Prayagraj Power Generation Ltd.

Work Instruction
Issue No. /
Doc. No. PPGCL/CHP/WI/01 01/31-03-2020
Date

Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

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Revision No/Date: R02/31/03/2020

Confidential & Proprietary – Prayagraj Power Generation Ltd.

 Prayagraj Power Generation Ltd. Work Instruction
Issue No. /
Doc. No. PPGCL/CHP/WI/01 01/31-03-2020
Date

Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

1. PURPOSE:

This procedure has been prepared to provide guidance to the concerned staff/Engineer to
carry out the, Inspection and Maintenance activity in manner that conforms to Quality,
environmental and Occupational health and safety requirements.

2. Scope: This procedures applicable for Preventive Maintenance of Dust suppression system
 Monthly Inspection and Maintenance
 Inspection and Maintenance after 8000Hrs
 Inspection and Maintenance after 16000Hrs

3. Responsibility:

a) All the operational staff is responsible to comply with this procedure.

b) Respective Core team members will prepare and update the procedure based on the need
for review expressed by the personnel or based areas identified for effective
implementation by the and Heads of the department during review or internal audits.
c) Heads of the departments shall approve the changes to this document.

4. Cross references:
OEM Manual

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 Prayagraj Power Generation Ltd. Work Instruction
Issue No. /
Doc. No. PPGCL/CHP/WI/01 01/31-03-2020
Date

Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

5. Procedure:

Sr. No. Activity

I WI for Dust Suppression System Inspection and Maintenance (O/H)
1 Take PTW of the Dust Suppression System and ensure LOTO has been carried out.
Brief the workmen about the job to be carried out and the safety precautions to be taken
2
and ensure clear understanding.
3 Ensure that the workmen are wearing the required Personal Protective Equipment.

4 Check the healthiness of tools and that lifting tools are certified.

5 Check ad ensure that all the nozzles are working properly and not choked up.
Check for the operation of big gun with a tilted riser.

7 Release the PTW.

Trial Operation of Dry Fog System.

 After completion of overhaul work of the DFS, take an operating permit from the
8
control room.
 Ask operation to line up the system and proceed for a trial run.
 Check for any abnormalities.

Sr. No. Activity

I WI for Dust Suppression Pump Inspection
1 Take PTW of the Dust Suppression System and ensure LOTO has been carried out.

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Prayagraj Power Generation Ltd. Work Instruction
Issue No. /
Doc. No. PPGCL/CHP/WI/01 01/31-03-2020
Date

Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

Brief the workmen about the job to be carried out and the safety precautions to be taken
2
and ensure clear understanding.
3 Ensure that the workmen are wearing the required Personal Protective Equipment.
4 Check the healthiness of tools and that lifting tools are certified.
5 Check for the pump gland leak and gland packing.
6 Check for the alignment of pump.
7 Check for the pump noise and vibration.
8 During overhauling of pump first check the clearance between casing and impeller.
9 Check for the erosion in impeller.
10 Check for the play in drive end and non-drive end bearing and replace it if needed.
11 Check for proper lubrication in bearings.
B W.I for D.S.S Pump Maintenance (O/H).
1 Before dismantling, make sure the motor is disconnected.
2 The suction and discharge shutoff valves must be closed.
3 The pump casing must have cooled down to ambient temperature.
4 The pump casing must be empty and not under pressure.
Detach all auxiliary supply pipe lines.
5
Remove coupling guard.
6 Remove coupling half from the pump shaft. Refer fig. no. 1
7 Pull out bearing bracket with discharge cover and complete rotor (assembled unit).
If the pump has been in operation for a long time some parts may be difficult to remove.
8
In this case use a penetrating oil or suitable pull-off device.
Loosen & remove impeller Lock nut.
9
Remove impeller from pump shaft.

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Issue No. /
Doc. No. PPGCL/CHP/WI/01 01/31-03-2020
Date

Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

Cross Sectional Drawing of C W Pump

10

11

Dismantling the Bearing Unit

12

Fig. no. 3: Dismantling the bearing unit

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Issue No. /
Doc. No. PPGCL/CHP/WI/01 01/31-03-2020
Date

Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

13 Remove bearing covers (360.01/02) and gaskets by unscrewing of hex. Bolt

Fasten the bearing unit (330) firmly to the bench vice refer fig. no. Strike the pump shaft
14
end with a soft hammer.
Fasten the shaft (with bearings) to the bench vice and detach bearings from shaft with a
15
bearing puller
Note: Always replace the bearings once they have been removed from the shaft with
new ones.

Unnecessary removal of the bearings should be avoided because removal of the bearing
16 can damage it and cause deterioration of the interference fit. Except where removal is
necessary to give access to the other parts, bearing should be removed only if they need
close inspection. Symptoms, which will indicate the state of bearing, are the condition of
the lubricant, the bearing running temperature, noise level and vibration during operation.

Shaft Sleeves
17 Replace shaft sleeve if it is grooved or generally worn.

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Doc. No. PPGCL/CHP/WI/01 01/31-03-2020
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Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

Impeller
a. Inspect the impeller as follows:
i. Examine the impeller for damage.
ii. For corrosive /erosion pitting.
iii. Cavitations pitting.
iv. Bent or cracked vanes, inlet and outlet vane end wear.

18

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Issue No. /
Doc. No. PPGCL/CHP/WI/01 01/31-03-2020
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Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

Any of the above may be repaired, or if damage is extensive, impeller may need
replacement.
b. Around the eye, wearing rings protects the impeller. Examine around the eye at
neck portion for grooving in alignment with spindle axis; slight grooving is
acceptable but deep or profuse grooving must be remedied by machining the
impeller by taking a polish cut on wearing ring. Spare wear rings are supplied with
excess outside diameter to facilitate machining after fitting. The wear rings are
shrink fitted on impeller neck and are screwed.
c. To check wear, around the impeller neck, use precision instruments such as
outside micrometer to accurately measure the outside diameter. Measurements
should be taken at intervals around the circumference to check the uneven wear.
Differences between the neck OD and the neck ring ID measured will give us the
clearance between the two. Clearance thus obtained should not be more than
150% of maximum designed clearance.

Shaft & keys

Shaft should be checked for the trueness, or any other mechanical damage and
corrosion. If the shaft is not true within 0.1 mm TIR, it should be replaced / repaired.
Examine the shaft keys and key ways. Remove damaged or worn out keys

19 Bearings

a. Clean all the components using clean white spirit. Do not use chlorinated solvents
such as trichloroethylene and carbon tetrachloride because they introduce a
corrosion risk when used on ferrous materials.
b. Visually inspect the bearing. The balls, the inner and outer tracks must all be free
from chipping cracks, abrasions or discoloration.
c. Check that the parts of the cage are firmly fixed together.
d. Visually inspect the bore for any sign of damage. Burrs or any scratches caused
during bearing withdrawal should be carefully removed by hand application of a
fine oilstone, the treatment being confined to the minimum possible area.
e. Visually inspect the outside diameter for signs of fretting, any stains may be
carefully polished off, but abrasion must be kept to the absolute minimum that is
required, followed by cleaning.
f. Check that bearing rotates freely and smoothly. If there is any doubt regarding the
serviceability of the bearing it should be replaced.
g. If after inspection, the bearing is reusable, completely coat all parts with rust
preventive oil, working it well into the internal parts of the bearing. Wrap in clean
greaseproof paper and store until required for replacement or refit on to the
spindle if needed. In case of immediate use, coating of rust preventive oil is not
necessary.

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Doc. No. PPGCL/CHP/WI/01 01/31-03-2020
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Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

Stuffing box bush

Check bore of stuffing box bush and compare with sleeve diameter. If "clearance is
20 excessive, the bush should be renewed.

Note: While assembling stainless steel component, molybdenum-disulphide paste

should be applied to prevent galling / seizure and also to facilitate easy removal in future.

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Doc. No. PPGCL/CHP/WI/01 01/31-03-2020
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Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

Reassembly
1. Coat the fits and screw connections with molykote or similar before reassembly.
2. Check oil seal & o-rings for its damage; replace if necessary.
3. All gaskets must be renewed; make sure the new ones have the same thickness
as the old ones.
4. Check the shaft (210) with its spacer sleeve (525) / or shaft protection sleeve
(524) (as applicable) for eccentricity, between centers. Maximum allowable
eccentricity is 0.05mm.
5. Fasten the shaft (210) to the bench vice using soft polish sheets between the vice
clamp jaws to avoid damage. Refer fig. no. A.
6. Heat the bearings (321.01/02) in the
induction heater about 80-90C max. and
push it on to the shaft. Fig. no. A Allow the
bearings to cool down. Then tap it lightly
against the shoulder using suitable pipe
punch.

21

(A)
7. Fit shaft circlip

Shaft assembly (B) Inner Bearing Cover assembly (C)

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Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

8. Vacuum and blow out all cavities of bearing housing.

Bearing Housing (D) (E)

9. Set bearing housing “D” vertical on flange.
10. Press in shaft assembly “B” as shown.
11. Fasten outer bearing cover assembly “C”.
12. Secure inner bearing cover assembly ”C”.

22 (F)
13. Fit deflectors at pump side
14. Fit coupling key.
15. Add PVC tape to secure.
16. Place back cover on bench.
17. Insert the packing / logging ring set into this stuffing box.
a. Before repacking, thoroughly clean stuffing box gland (452), packing
compartment and shaft protection sleeve (524).
b. Cut the packing ring to correct length and ends at 45º. Ensure that the packing
rings ends come into contact with one another on fitment.

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Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

c. In the case of asbestos-graphite packing material, the rubbing faces of the

individual rings should be lightly coated with MOLYKOTE before insertion in the
packing compartment. The first packing ring is then inserted and pushed home
into the compartment with aid of the stuffing box gland (452).

d. The following packing rings are then inserted into the packing compartment one
by one, making sure that the butt joint of each ring is offset by 900 approx. in
relation to the butt joint of the preceding ring. The individual rings are pushed
home into the packing compartment with the stuffing box gland (452).

e. The inserted packing rings should then be compressed moderately with the aid of
the stuffing box gland (452) and the nuts (920). Then the nuts (920) should be
slackened again by one to two complete turns, and thereafter tightened lightly by
hand.

f. The correct and even seating of the stuffing box gland (452) should be checked
when the pump is subjected to suction pressure, by inserting a feeler gauge
between the stuffing box gland (452) and the shaft protection sleeve (524).

g. A lantern ring (458) is also inserted in the packing compartment, at the position
shown in the cross-sectional drawing. The lantern ring must register beneath the
drilled hole in the discharge cover (163), to enable the sealing liquid to enter.
23

Back Cover with Gland

& bush (G)
(H)

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Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

18. Place back cover on bench.

19. Fasten back cover assembly “G” to bearing housing assembly.

20. Rotate shaft & check for rubbing.

21. Fit impeller key tightly and apply. “Locktite” anti seize compound to shaft.
24
22. Tap impeller lightly into place.

23. Tighten impeller nut, holding the shaft steady at coupling end.

24. Check operating gap 0.5-1.5 mm.

25. Lightly grease” O” ring & fit.

K W.I for Compressor Maintenance.
Check Service Readings (air, oil, water temperature and pressure)
 Oil temperature
 Oil Pressure
 Air temperature, low-pressure element out
1  Air temperature, high pressure element out
 Air temperature, high-pressure element in
 Air outlet temperature
 Cooling water inlet temperature
 Cooling water outlet temperature
2 Check cooler functions (approach temperature)
3 Change intercooler condensate check valve
4 Check for air, water and oil leakage
5 Check for presence of water in lube oil
6 Inspect/change air filter elements
7 Replace filter element of gear case breather
8 Check cycle of air intake throttle valve
9 Check/Service condensate drains
10 Check rubber inserts of drive coupling
Preventive Maintenance (B Type) to be done after every 8000 running hours as per
L
Checklist: CGPL-MMD-WI-01-B

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Doc. No. PPGCL/CHP/WI/01 01/31-03-2020
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Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

Check Service Readings (air, oil, water temperature and pressure)

 Oil temperature
 Oil Pressure
 Air temperature, low-pressure element out
1  Air temperature, high pressure element out
 Air temperature, high-pressure element in
 Air outlet temperature
 Cooling water inlet temperature
 Cooling water outlet temperature
2 Check cooler functions (approach temperature)
3 Change intercooler condensate check valve
4 Check for air, water and oil leakage
5 Check for presence of water in lube oil
6 Inspect/change air filter elements
7 Replace filter element of gear case breather
8 Check cycle of air intake throttle valve
9 Check/Service condensate drains
10 Check rubber inserts of drive coupling
Check operation of safety valves
 Low-pressure safety valve
11
 High-pressure safety valve
12 Change compressor oil filter
13 Replace diaphragm of air throttle valve
14 Replace bearing block (air intake valve)
15 Check functioning of check valve
16 Check condition of balance piston diaphragm
Preventive Maintenance (C Type) to be done after every 16000 running hours as
M
per Checklist: CGPL-MMD-WI-01-C
Check Service Readings (air, oil, water temperature and pressure)
 Oil temperature
 Oil Pressure
 Air temperature, low-pressure element out
 Air temperature, high pressure element out
1
 Air temperature, high-pressure element in
 Air outlet temperature
 Cooling water inlet temperature
 Cooling water outlet temperature
2 Check cooler functions (approach temperature)

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Title WI for FR Grade Conveyor Belt: Inspection & Maintenance (Joint Checking / Repairing)

Check operation of safety valves

 Low-pressure safety valve
3
 High-pressure safety valve
4 Change intercooler condensate check valve
5 Check for air, water and oil leakage
6 Check for presence of water in lube oil / Change Roto Z oil
7 Inspect/change air filter elements
8 Replace filter element of gear case breather
9 Check cycle of air intake throttle valve
10 Check/Service condensate drains
11 Inspect / Replace inserts of drive coupling
12 Change compressor oil filter
13 Replace diaphragm of air throttle valve
14 Replace bearing block (air intake valve) / Overhaul air intake valve
15 Check functioning of check valve / Overhaul check valve
16 Check / Replace balance piston diaphragm
17 Service intercooler blow down valve

6. Records :

PM Checklist
Document No.- CGPL/IMS/CHP/19, CGPL/IMS/CHP/11

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